GROUP 12 REAR AXLE

1. REMOVAL REAR AXLE

1) Rear axle mounting bolt(1, M24)
şTightening torque : 58 Ź6.3(kgfşm)
(419.5 Ź45.6lbfşft) 1
2) Propeller shaft mounting bolt(2, M10)
şTightening torque : 5.9 Ź0.6kgfşm
4
(42.7 Ź4.3lbfşft)
3) Wheel nut(3, M22)
+0
şTightening torque : 60 -5 kgfşm
0
(434 -36 lbfşft)
2
4) Hose assy(4, PF 3/8) 3
şTightening torque : 5kgfşm(36.2lbfşft)
5) Axle weight : 490kg(1080lb)

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2. GENERAL INSTRUCTIONS
1) GENERAL WORKING INSTRUCTIONS
(1) This manual has been developed for the skilled serviceman, trained by axle manufacturer.
(2) During all operations, pay attention to cleanliness and skilled working.
Therefore, axle removed from the machine, must be cleaned prior to open them.
(3) We assume that the special tools, specified by manufacturer, will be used.
The special tools are available from manufacturer.
(4) After the disassembly, all components must be cleansed, especially corners, cavities and
recesses of housing and covers.
(5) The old sealing compound must be carefully removed.
(6) Check lubricating holes, grooves and pipes for free passage. They must be free of residues,
foreign material or protective compounds.
(7) The latter refers especially to new parts.
(8) Parts which have been inevitably damaged in a disassembly operation, must be generally
replaced by new ones, e.g. rotary seal rings, O-rings, U-section rings, cap boots, protective caps
etc..
(9) Components such as roller bearings, thrust washers, synchronizing parts etc. which are subject to
normal wear in automotive operation, must be checked by the skilled Serviceman.
He will decide if the parts can be reused.
(10) For the heating of bearings etc., hot plates, rod heaters or heating furnaces must be used.
(11) Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing in
a vessel filled with oil, which is then heated with the flame.
In this way, damage to the bearings could be avoided.
(12) Ball bearings, covers, flanges and parts like that must be heated to about 90 to 100Ş
C.
(13) Hot-mounted parts must be reset after cooling in order to assure a proper contact.
(14) Before pressing shafts, bearings etc. in position, both parts must be lubricated.
(15) During to reassembly, all specified adjustment values, testing specifications and tightening torque
must be respected.
(16) After the repair, units are filled up with oil.
(17) After the oil filling, the oil level plugs and oil drain plugs must be tightened to the specified
tightening torque.

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2) IMPORTANT INSTRUCTIONS CONCERNING THE LABOUR SAFETY
(1) In principle, repairers are themselves responsible for the labour safety.
(2) The observance of all valid safety regulations and legal rules is a precondition to prevent damage
to individuals and products during the maintenance and repair operations.
(3) Before starting the work, the repairers have to make themselves familiar with these regulations.
(4) The proper repair of these products requires especially trained personnel.
(5) The repairer himself is obliged to provide for the training.
3) LUBRICANT SPECIFICATIONS
(1) Gear oils with limited - slip additives.
(2) API GL-5
(3) MIL-L-2105D(SAE 85W-90, 85W-140 with LS-Additive)

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4) BRAKE LINING WEARING TEST
(1) General
‫ ڸ‬The brake lining wearing test gives a limited information about the overall condition of the brake
plate pack - without disassembly of the planetary carrier, resp. of the plates.
‫ ڹ‬The wearing test has to be carried out in case of the following criteria :
- In the course of the oil change intervals
- Braking noises
- Reduced braking power
- Change of deceleration of the brake fluid level as well as of the brake pressure
- In case of a general change of the brake performance.
‫ ں‬Carry out the wearing test on both final drive sides.
- Permitted piston stroke max. : 6.25mm
- Piston stroke in new condition of the plate pack : 2.4~2.8mm
(2) Carry out the wearing test
‫ ڸ‬Turn the planetary carrier until screw plug
A
A(M16ź1.5) is in the upper position(12
o'clock position).
Now, remove the screw plug.
‫ڹ‬ Apply the brake(Required brake
pressure min. 40bar). el
lev
‫ں‬ Screw measuring screw(M16ź1.5) in Oil

until contact is obtained and tighten it

with a torque of 1kgşm.
‫ڻ‬ Determine dimension X according to the
figure on the right.
‫ڼ‬ Release the brake and equalize the plate
clearance by resetting the measuring
screw.
X
Torque limit 1kgşm.
‫ڽ‬ Determine dimension Y according to the
figure on the right.
‫ھ‬ The difference of the two dimensions
(X-Y) corresponds to the piston stroke
(Actual state).
(3) Result
If the max. permitted piston stroke(5.0mm)
is exceeded, the lining plates must be
renewed on both final drive sides.

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